Footwear manufacture

Abstract

A method of manufacture of a piece of a footwear upper is provided. The piece is formed from a sheet which is folded to form a lamination. A method for forming a footwear upper which comprises at least one such piece is provided, wherein a folded edge of the piece then forms part of an opening of the finished footwear upper. Also provided are a piece of a footwear upper, and a footwear upper according to the methods provided.

1 . A method of forming a piece of a footwear upper comprising:
 providing a sheet of material;   folding the sheet;   forming a lamination from the folded sheet.   
     
     
         2 . A method according to  claim 1 , comprising the further step of molding the piece to a suitable three dimensional configuration. 
     
     
         3 . A method according to  claim 2 , wherein the molding includes placing the piece into a heat press molding apparatus including complementary shaped first and second molding portions, wherein the first molding portion is configured to receive a complementary second molding portion so that the piece is formed into a three dimensional configuration therebetween. 
     
     
         4 . A method according to  claim 1 , comprising the further step of trimming the piece to the desired size such that an edge of the piece comprises a folded edge of the folded sheet lamination. 
     
     
         5 . A method according to  claim 1 , comprising the further step of providing cushioning between the folded sheet before the lamination is formed. 
     
     
         6 . A method according to  claim 1 , wherein the sheet of material is molded into a three dimensional precursor configuration before being folded. 
     
     
         7 . A method according to  claim 6 , wherein the three dimensional precursor configuration includes at least one recess configured to receive cushioning. 
     
     
         8 . A method according to  claim 1 , wherein the sheet of material has more than one layer. 
     
     
         9 . A method of forming a footwear upper comprised of one or more pieces which are attached together, wherein at least one of the pieces is formed as described in  claim 1 , and wherein the pieces are configured such that an opening of the upper is defined by at least part of the folded edge of the folded sheet lamination. 
     
     
         10 . A method of forming a footwear upper according to  claim 9 , wherein the pieces are ultrasonically welded. 
     
     
         11 . A method of forming a footwear upper according to  claim 9 , wherein the pieces are sewn. 
     
     
         12 . A method of forming a footwear upper according to  claim 9 , wherein the pieces are attached with adhesive. 
     
     
         13 . A method of forming a footwear upper according to  claim 10 , with the additional step of providing a strip of material to at least partially cover a join between pieces. 
     
     
         14 . A method of forming an article of footwear, wherein the footwear upper or pieces of the footwear upper are formed as claimed in  claim 1 . 
     
     
         15 . A piece of a footwear upper comprising a lamination which has been formed from a folded sheet. 
     
     
         16 . A piece of a footwear upper according to  claim 15  which has further been molded to a suitable three dimensional configuration. 
     
     
         17 . A piece of a footwear upper according to  claim 15  which has been trimmed such that an edge of the piece comprises a folded edge of the folded sheet lamination. 
     
     
         18 . A piece of a footwear upper according to  claim 15  which further comprises cushioning disposed within the lamination. 
     
     
         19 . A piece of a footwear upper according to  claim 15  wherein the sheet which forms the lamination has more than one layer. 
     
     
         20 . A footwear upper comprising:
 one or more pieces, wherein at least one of the pieces is a piece as claimed in  claim 15 ; and   an opening which is at least partly defined by at least part of a folded edge of a folded sheet lamination.   
     
     
         21 . A footwear upper according to  claim 20 , wherein at least some of the pieces have been joined by ultrasonic welding. 
     
     
         22 . A footwear upper according to  claim 20 , wherein at least some of the pieces have been joined by stitching. 
     
     
         23 . A footwear upper according to  claim 20 , wherein at least some of the pieces have been joined with adhesive. 
     
     
         24 . A footwear upper according to  claim 21 , wherein at least part of a join between pieces is covered by a strip of material. 
     
     
         25 . An article of footwear comprising a footwear upper, or a piece of footwear upper, as claimed in  claim 15 . 
     
     
         26 . A method of forming a footwear upper comprised of one or more pieces which are attached together, wherein at least one of the pieces is formed according to the following steps:
 providing a sheet of material;   molding the sheet into a suitable three-dimensional precursor configuration, wherein
 the precursor configuration includes at least one recess configured to receive cushioning; 
   providing cushioning to the sheet;   folding the sheet;   forming a lamination from the folded sheet, wherein
 the cushioning is between the folded sheet; 
   molding the folded sheet lamination to a suitable three-dimensional configuration;   trimming the molded lamination to the desired size such that an edge of the piece comprises a folded edge of the folded sheet lamination;   and wherein the pieces are configured such that an opening of the footwear upper is defined by at least part of the folded edge of the folded sheet lamination.   
     
     
         27 . A footwear upper comprising:
 one or more pieces, wherein at least one of the pieces comprises:
 a lamination which has been formed from a folded sheet, and which has been molded into a suitable three-dimensional configuration; and 
 cushioning disposed within the lamination; and 
   an opening which is at least partly defined by at least part of a folded edge of the folded sheet lamination.